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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Bio-project “derisking” through development of systematic methodologies and frameworks for risk assessment

One of the primary hindrances to producing a viable, sustainable domestic biomass industry for renewable biofuels, bio-products and bio-power is the lack of understanding and quantification of the risks associated with both the biomass supply chain and preprocessing and conversion technologies. Currently a consistent method for assessing, comparing, and quantifying risks in biomass supply chains does not exist, creating a major investment barrier to bioenergy projects in the U.S. The lack of a standardized approach has resulted in bioenergy stakeholders independently using inconsistent approaches and evaluation criteria, leading to unreliable and incomparable assessments of risks and financing barriers to bio-project development. Along with the challenges of inconsistent risk assessment for supply chain risk, technology specific risks based on variability in biomass properties are not fully understood and can pose significant unforeseen challenges for bioenergy projects. In many cases these properties have not yet been identified and the impacts on the proposed technology and products unquantified. This is particularly challenging for emerging preprocessing and conversion technologies. Without a firm understanding of the preprocessing/conversion technology-specific critical properties, the risk of a proposed bio-project cannot be fully evaluated. To address inconsistent risk evaluation in the biomass supply chain supporting project financing, a Biomass Supply Chain Risk Standards (BSCRS) framework was developed. The BSCRS framework includes a comprehensive list of known and perceived risks (Risk Indicators) to the supply chain developed through 100’s of interviews with bioenergy industry experts spanning from feedstock growers and suppliers to representatives from the financial sector. These risks have been organized into a manageable hierarchy of Risk Categories and Risk Factors that can be practically assessed. This BSCRS framework also provides mitigation strategies for multiple Risk Indicators from best available industry practices and research findings. Additionally, a risk quantification methodology for each Risk Factor, Risk Category, and the bio-project as a whole was developed to enable capital markets to assess feedstock risk more efficiently and more accurately. Multiple case studies representing existing bio-projects have been used to evaluate and verify the BSCRS framework and scoring methodology. To address technological risk along with the supply chain risk captured in the developed BSCRS framework, this work also focuses on development of a systematic criticality assessment tool using well-accepted, quantitative risk analysis methods to evaluate bioenergy feedstock critical properties impacting system unit operations. The proposed Failure Mode and Effect Analysis (FMEA) approach uses a team of subject area experts (SAEs) for each targeted unit operation within a system. Collectively, the team will develop and use a quantitative scoring system to assess the material attributes, process parameters, and quality attributes for key unit operations that have already been identified. The FMEA process generates Risk Priority Numbers (RPNs) for the various failures and predominant causes for each material/process unit/product combination resulting in a semi-quantitative, standardized methodology for assessing technological risk and biomass properties contributing to that risk.

09 BIOMASS FUELS↗
DOE OSTI2023

Catalytic Upgrading of Pyrolysis Products for the Production of Sustainable Aviation Fuel

The objective of this project is advance the state-of-technology for a catalytic fast pyrolysis (CFP) + hydrotreating (HT) process to produce sustainable aviation fuel and other biogenic products. Our approach focuses on performing integrated experiments using realistic biomass feedstocks and non-noble metal technical catalyst formulations. CFP is performed in an ex-situ configuration using a fluidized bed reactor without co-fed hydrogen. Research advancements over the past two years include establishing benchmark yield structures and compositional data for each step of the biomass-to-SAF process, demonstrating the ability to produce a cycloalkane-rich SAF product that meets key ASTM 4054 guidelines, generating benchmark characterization data for technical catalyst formulations with an emphasis on determining the unique composition and combustion properties of biogenic coke, and establishing bio-oil critical material attributes to mitigate the risk of plugging during down-stream hydroprocessing. Other impacts from this project include generation of broadly enabling scientific knowledge (12 publications/12 presentations since 2021), engagement with industry partners (Johnson Matthey, ExxonMobil, Phillips 66), and identification of a promising pathway to market that addresses emerging demands for biogenic refinery feedstocks.

biomass↗
NASA NTRS1977

The radiation history of material returned by the Soviet automatic stations Luna 16 and Luna 20, according to track studies

Fission tracks formed by the vH (very heavy) nuclei group of solar and galactic cosmic rays have been studied in silicate minerals of the lunar regolith returned by the Luna 16 and Luna 20 unmanned spacecraft. It is shown that the material in the Luna 16 core sample, from a typical mare region of the lunar surface, has undergone stronger irradiation by cosmic rays than material returned a highland region by Luna 20. A low-irradiation component (about 10 percent of the total number of crystals) has been found in the Luna 20 core sample materials, which can possibly be attributed to material added to the main bulk of the regolith in the formation of the crater Apollonius C. From the track density distribution of crystals, as a function of depth in the regolith core sample, it follows that the process of formation of the upper layer of the regolith, both for the lunar mare and for the highland region, includes sequential layering of finely crushed crystalline matter and subsequent mixing of it by micrometeorite bombardment. A portion of the crystals with a very high track density may be a component added to the lunar surface from outer space.

Kashkarov, L. L.↗
DOE OSTI2021

Bayesian constraints on the origin and geology of exoplanetary material using a population of externally polluted white dwarfs

ABSTRACT White dwarfs that have accreted planetary bodies are a powerful probe of the bulk composition of exoplanetary material. In this paper, we present a Bayesian model to explain the abundances observed in the atmospheres of 202 DZ white dwarfs by considering the heating, geochemical differentiation, and collisional processes experienced by the planetary bodies accreted, as well as gravitational sinking. The majority (>60 per cent) of systems are consistent with the accretion of primitive material. We attribute the small spread in refractory abundances observed to a similar spread in the initial planet-forming material, as seen in the compositions of nearby stars. A range in Na abundances in the pollutant material is attributed to a range in formation temperatures from below 1000 K to higher than 1400 K, suggesting that pollutant material arrives in white dwarf atmospheres from a variety of radial locations. We also find that Solar System-like differentiation is common place in exoplanetary systems. Extreme siderophile (Fe, Ni, or Cr) abundances in eight systems require the accretion of a core-rich fragment of a larger differentiated body to at least a 3σ significance, whilst one system shows evidence that it accreted a crust-rich fragment. In systems where the abundances suggest that accretion has finished (13/202), the total mass accreted can be calculated. The 13 systems are estimated to have accreted masses ranging from the mass of the Moon to half that of Vesta. Our analysis suggests that accretion continues for 11 Myrs on average.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS2007

Improved C/SiC Ceramic Composites Made Using PIP

Improved carbon-fiber-reinforced SiC ceramic-matrix composite (C/SiC CMC) materials, suitable for fabrication of thick-section structural components, are producible by use of a combination of raw materials and processing conditions different from such combinations used in the prior art. In comparison with prior C/SiC CMC materials, these materials have more nearly uniform density, less porosity, and greater strength. The majority of raw-material/processing-condition combinations used in the prior art involve the use of chemical vapor infiltration (CVI) for densifying the matrix. In contrast, in synthesizing a material of the present type, one uses a combination of infiltration with, and pyrolysis of, a preceramic polymer [polymer infiltration followed by pyrolysis (PIP)]. PIP processing is performed in repeated, tailored cycles of infiltration followed by pyrolysis. Densification by PIP processing takes less time and costs less than does densification by CVI. When one of these improved materials was tested by exposure to a high-temperature, inert-gas environment that caused prior C/SiC CMCs to lose strength, this material did not lose strength. (Information on the temperature and exposure time was not available at the time of writing this article.) A material of the present improved type consists, more specifically, of (1) carbon fibers coated with an engineered fiber/matrix interface material and (2) a ceramic matrix, containing SiC, derived from a pre-ceramic polymer with ceramic powder additions. The enhancements of properties of these materials relative to those of prior C/SiC CMC materials are attributable largely to engineering of the fiber/ matrix interfacial material and the densification process. The synthesis of a material of this type includes processing at an elevated temperature to a low level of open porosity. The approach followed in this processing allows one to fabricate not only simple plates but also more complexly shaped parts. The carbon fiber reinforcement in a material of this type can be in any of several alternative forms, including tow, fabric, or complex preforms containing fibers oriented in multiple directions.

Easler, Timothy↗
NASA NTRS1973

Fabrication and Improvement of Lmsc's All-silica RSI

The LI-1500 and LI-900 all silica RSI materials have made the transition from laboratory to manufacturing operation. Improvements in both quality and reproducibility have been achieved. The LI-1500 material has displayed superior reliability in evaluations conducted at various facilities. The dependable performance of the material is attributed to the adherence to the stringent requirements of the numerous material, process, and product control evaluations and inspection points performed during manufacture.

Beasley, R. M.↗
DOE OSTI2025

A case study in contrastive learning information combination: Application to technical forensics of additive manufacturing filament source identification

Combination of information from disparate data sources into a single decision is a core challenge in many fields, including the field of technical forensics. Technical forensics (TF) utilizes technical characterization of questioned samples to determine properties of that sample; these properties are then used to infer information of forensic interest, such as provenance, age, or attribution. TF is utilized in traditional forensic applications, such as the attribution of material fragments from an explosive, and in nuclear forensic applications, such as the attribution of actinides which have been interdicted out of regulatory control. The challenge of combining information from disparate sources, described alternately by many terms including “Data Fusion” and “Data Integration”, is exacerbated in the technical forensics domain due to at least two factors: the challenge of interpreting each information source singularly, and the relatively small data set sizes available. Extensive literature exists attempting to combine technical forensics information sources, both in manual and automated processes. These attempts are often bespoke to the specific information sources (such as the bi-, tri-, or quad-isotope chart (Moody, Grant, and Hutcheon 2005)), with some emerging examples of simple early- and late- fusion (, respectively). Simultaneous to the information combination efforts described in the previous paragraph, the field of natural language processing attempted (and largely succeeded) in combining information from multiple non-technical information sources. The ecosystem of “multi-modal” language models, which can take text and images as input, and generate text and images as output, became large and diverse by 2025 (Khan et al. 2025). In a generalized sense, many of these methods are trained by learning neural networks which can convert raw text or images into a vector of numbers describing the text or image, hereafter called “embeddings” and the neural networks performing the conversion are called “embedders”. By using a separate embedder for text and images, finding coincident text and images (such as images with their captions), and optimizing the parameters of the embedders such that the embeddings for the text and the image are similar, the field has found a bridge between text and images (Girdhar et al. 2023). It is the contention of the authors of this report that this insight is not limited to text and images but instead can be extended to any modality which can be found coincidently. The subject of the rest of this report is the application of this method to example multi-modal technical forensic data. Some details about the data used in this report are not appropriate for this report, and are included in a companion report (PNNL-38669).

36 MATERIALS SCIENCE↗
DOE OSTI2023

Twin-screw granulation: Mechanistic understanding of the effect of material properties on key granule quality attributes through the analysis of mixing dynamics and granulation rate mechanisms

This study focuses on understanding the effect of material properties on granule quality attributes through the analysis of mixing dynamics and granulation rate mechanisms. Powder wettability, binder viscosity, and liquid-to-solid (L/S) ratio were the factors that were investigated in this study. Further, the mixing occurring inside the twin-screw granulator (TSG) was quantitatively assessed by obtaining the axial dispersion coefficient from the experimentally measured residence time distribution (RTD) curves. It was observed that the quality of the nuclei fed to the kneading zone significantly affected the mixing dynamics. The quality of nuclei was governed by nucleation kinetics, which in turn was principally affected by the liquid saturation of the nuclei and the ratio of drop penetration time and encounter time, which in turn were affected by the L/S ratio and binder viscosity respectively. The hydrophobicity of the blend mainly affected the extent of nucleation. The type of nuclei entering the kneading zone and mixing dynamics in the TSG also determined whether the granulation growth mechanism was “layering-dominant” or “viscous-dominant”. It was also shown that the resultant granule quality attributes were a reflection of the growth mechanisms. Ultimately, a mechanistic link between material properties, mixing dynamics, granulation rate mechanisms, and granule quality attributes was established.

36 MATERIALS SCIENCE↗
NASA NTRS1999

Are Hyperion and Phoebe Linked to Iapetus?

Narrowband reflectance spectra of the Saturnian satellites S VII Hyperion and S IX Phoebe were obtained across the 0.4 - 0.8 micron spectral region. The spectrum of Phoebe is similar to the spectrum of a C-class asteroid, with an absorption feature centered near 0.43 micron superimposed on the UV/blue intervalence charge transfer transition present in the spectrum. The spectrum of Hyperion shows the strong spectral slope apparent in spectra of many outer Solar System materials and attributed to organics. We use a linear mixing model to separate the reflectance spectrum of the dark material on Hyperion from the icy material. A distinct absorption feature centered at 0.67 micron is present. A slight inflection near 0.4 - 0.6 micron and change in slope near 0.73 micron suggesting the lower wavelength edge of an absorption are also present. These absorptions are very similar to those identified in the spectrum of the dark material on the surface of Iapetus, suggesting that the dark material on these two satellites is compositionally similar and has a similar origin. These absorption features are attributed to the (6)A(sub 1) yields (4)T(sub 2)(G) and (6)A(sub 1) yields (4)T(sub 1)(G) ferric charge transfer transitions in iron alteration minerals such as goethite and hematite that are products of the aqueous alteration of anhydrous silicates.

Jarvis, Kandy S.↗
DOE OSTI2020

Recent Advances in Nuclear Forensic Chemistry

Nuclear forensics is a rapidly growing field with a widespread impact on global nonproliferation. From the beginning, nuclear forensic capabilities have been inextricably bound to existing limitations within chemistry and materials science. As nuclear forensics has continued to develop as a unique field of research, new advances in chemistry have revolutionized our ability to rapidly and quantitatively analyze radioactive materials for attribution. In particular, microanalytical techniques originally developed for nanoscience, such as micro-XRF, SIMS, and SEM-EDX, have enabled spatially resolved chemical analyses to be performed with only nanograms of material. Such techniques have redefined the paradigm for pre- and postdetonation nuclear forensics, as large quantities of material are no longer necessary for full characterization and attribution. This Review explains how modern nuclear forensic techniques have developed from their origins in chemistry and provides real-world examples of how these techniques have been used to characterize radioactive materials, including fallout from nuclear detonations such as the 1945 Trinity test.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
NASA NTRS1994

Light-Hydrocarbon Bearing Solids on Planetesimal 5145 Pholus

Object 5145 Pholus (=1992 AD) is a planetesimal in an orbit that crosses those of Saturn, Uranus, and Neptune (period 92.7 years). It is particularly notable because of its extreme red color, corroborated by several observing teams. A spectrum of Pholus obtained in 1992 shows a strong absorption band with a characteristic shape at 2.27 micrometers, plus a weaker band at 1.7 micrometers. A better spectrum of the 2.0-2.5 micrometer region in 1993 confirms the position and shape of the 2.27-micrometer band. The color and spectral bands are identified with the aliphatic-rich and high H/C organic solid called asphaltite, which in a terrestrial setting originates from thermal processing of products of biological activity. In Pholus, this material is attributed to formation from radiation processing of ices on grains in the interstellar medium. Laboratory spectra of asphaltite and related materials have been published by Moroz et al., while Cloutis showed similar bands in comparable materials and identified them as the overtone and combination bands of C-H stretching and bending modes in CH2 and CH3 groups. Asphaltites, kerites, and anthraxolites are solid non-graphite members of a sequence ranging from oil to graphite; diffuse reflectance spectra of suites of these intermediate materials show color characteristics similar to those of the low-albedo asteroids (C,P,D), although specific identifications have not been made because of the lack of distinct absorption bands in the spectra of most low-albedo solar system bodies. In the case of Pholus, however, the primary band is strong; its wavelength and its shape, plus the match of the extremely red color, leads us to the identification of aliphatic-rich, asphaltite-like organic solid. The C, P, and D-type asteroids vary in degree of "redness", but are all less red than Pholus. Pholus and the Ctype asteroids are the end members of a sequence that represents the radiation processing of hydrocarbons, with Pholus being the least processed. Solar irradiation processes and heating reduce the H/C and aliphatic content of hydrocarbons preserved from the interstellar medium, and in the end produce opaque solids of neutral reflectance, including the kerogens (similar to anthraxolites) found in profusion in the carbonaceous meteorites.

Cruikshank, Dale P.↗
NASA NTRS1994

Light-Hydrocarbon Bearing Solids on Planetesimal 5145 Pholus

Object 5145 Pholus (=1992 AD) is a planetesimal in an orbit that crosses those of Saturn, Uranus, and Neptune (period 92.7 years). It is particularly notable because of its extreme red color, corroborated by several observing teams. A spectrum of Pholus obtained in 1992 shows a strong absorption band with a characteristic shape at 2.27 micron, plus a weaker band at 1.7 microns. A better spectrum of the 2.0-2.5 micron region in 1993 confirms the position and shape of the 2.27 micron band. The color and spectral bands are identified with the aliphatic-rich and high H/C organic solid called asphaltite, which in a terrestrial setting originates from thermal processing of products of biological activity. In Pholus, this material is attributed to formation from radiation processing of ices on grains in the interstellar medium. Laboratory spectra of asphaltite and related materials have been published by Moroz et al., while Cloutis showed similar bands in comparable materials and identified them as the overtone and combination bands of C-H stretching and bending modes in CH2 and CH3 groups. Asphaltites, kerites, and anthraxolites are solid non-graphite members of a sequence ranging from oil to graphite; diffuse reflectance spectra of suites of these intermediate materials show color characteristics similar to those of the low-albedo asteroids (C,P,D), although specific identifications have not been made because of the lack of distinct absorption bands in the spectra of most low-albedo solar system bodies. In the case of Pholus, however, the primary band is strong; its wavelength and its shape, plus the match of the extremely red color, leads us to the identification of aliphatic-rich, asphaltite-like organic solid. The C, P, and D-type asteroids vary in degree of 'redness', but are all less red than Pholus. Pholus and the C-type asteroids are the end members of a sequence that represents the radiation processing of hydrocarbons, with Pholus being the least processed. Solar irradiation processes and heating reduce the H/C and aliphatic content of hydrocarbons preserved from the interstellar medium, and in the end produce opaque solids of neutral reflectance, including the kerogens (similar to anthraxolites) found in profusion in the carbonaceous meteorites.

Cruikshank, Dale P.↗
NASA NTRS1999

Overview of Photonic Materials for Application in Space Environments

Future space systems will he based on components evolving from the development and refinement of new and existing photonic materials. Optically based sensors, inertial guidance, tracking systems, communications, diagnostics, imaging and high speed optical processing are but a few of the applications expected to widely utilize photonic materials. The response of these materials to space environment effects (SEE) such as spacecraft charging, orbital debris, atomic oxygen, ultraviolet irradiation, temperature and ionizing radiation will be paramount to ensuring successful space applications. The intent of this paper is to, address the latter two environments via a succinct comparison of the known sensitivities of selected photonic materials to the temperature and ionizing radiation conditions found in space and enhanced space environments Delineation of the known temperature and radiation induced responses in LiNbO3, AlGaN, AlGsAs,TeO2, Si:Ge, and several organic polymers are presented. Photonic materials are realizing rapid transition into applications for many proposed space components and systems including: optical interconnects, optical gyros, waveguide and spatial light modulators, light emitting diodes, lasers, optical fibers and fiber optic amplifiers. Changes to material parameters such as electrooptic coefficients, absorption coefficients, polarization, conductivity, coupling coefficients, diffraction efficiencies, and other pertinent material properties examined for thermo-optic and radiation induced effect. Conclusions and recommendations provide the reader with an understanding of the limitations or attributes of material choices for specific applications.

Taylor, E. W.↗
DOE OSTI2021

Nanomechanical mapping and strain rate sensitivity of microcrystalline cellulose

Nanoindentation provides a convenient and high-throughput means for mapping mechanical properties and for measuring the strain rate sensitivity of a material. Here, nanoindentation was applied to the study of microcrystalline cellulose. Here, constant strain rate nanoindentation revealed a depth dependence of nanohardness and modulus, mostly attributed to material densification. Nanomechanical maps of storage modulus and hardness resolved the shape and size of voids present in larger particles. In smaller, denser particles, however, where storage modulus varied little spatially, there was still some spatial dependence of hardness, which can be explained by cellulose’s structural anisotropy. Additionally, hardness changed with the indentation strain rate in strain rate jump tests. The resulting strain rate sensitivity values were found to be in agreement with those obtained by other techniques in the literature.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Design of an Integrated Solids Handling System to Maximize Syngas Process Reliability (Cooperative Research and Development Final Report)

The National Renewable Energy Laboratory (NREL), in partnership with Wonderful Renewable Energy (WRE) and Idaho National Laboratory (INL), plans to develop a general methodology for designing integrated biorefinery solids preprocessing, handling, and feeding systems based on the chemical, physical, and mechanical attributes of the starting biomass material. This attribute-driven approach will include detailed feedstock property measurements, iterative computational modeling, and bench-scale testing to design systems for preprocessing, handling, and reactor in-feed, up to and including the selection of the conversion reactor. The initial tests and system design will be conducted using waste material from almond and pistachio growing and production operations (shells, hulls, and wood), targeting the conversion of this material to syngas for electricity production. The methodology will then be generalized to other feedstocks. The purpose of this project is to design an integrated solids handling system to maximize the process reliability of converting almond and pistachio waste to electricity. The design methodology and workflow developed from this example will then be applied to the Feedstock Conversion Interface Consortium (FCIC) benchmark loblolly pine residues, thus demonstrating the robustness of the overall design approach and providing insight and guidance for future conversion systems. V-Grid Energy Systems was brought on as a subcontractor to provide gasifiers and labor to complete gasifier runs.

09 BIOMASS FUELS↗
DOE OSTI2022

Critical heat flux on zircaloy and accident tolerant fuel cladding under prototypical conditions of pressurized and boiling water reactors

First of a kind high spatial and temporal resolution temperature measurements of Pressurized Water Reactor and Boiling Water Reactor simulated fuel pins (high heat flux cosine profile heaters) in annular rod type geometry during nucleate boiling, departure from nucleate boiling and re-wetting has been performed. Distributed fiber optic measurements of the cladding axial temperature with spatial resolutions down to 2.5 mm axially at up to three equally spaced azimuthal locations per rod have demonstrated the similarities and differences of the different accident tolerant fuel cladding materials. These experiments show the performance of accident tolerant cladding with a precise measurement of the location and evolution of dryout followed by the re-wetting phenomena (see supplementary time history of a critical heat flux event). Experimental parameters varied coolant mass fluxes from 1695 to 2712 kg/m 2 s, pressures from 10 to 20 MPa, and inlet subcooling from 10 to 55 °C. It was found that the coatings and different material have little effect on the value of the critical heat flux. Any discrepancies between the local critical heat flux verified among the cladding material are attributed to different departure from nucleate boiling phenomena captured during the experiment with the high-resolution optical fiber temperature data. Substantial differences in the performance of the different cladding material to survive a critical heat flux event were however observed by post-test X-ray and optical inspection. External evident damage and internal cracks to the simulated fuel pin having the bare zircaloy cladding were observed in regions associated with the occurrence of the critical heat flux for longer periods. Such damages were associated with zirconium oxidation, and not noticed on the Cr coated zircaloy or FeCrAl claddings. These results indicate that the use of FeCrAl or a Cr coated zircaloy as cladding in Pressurized Water Reactor and Boiling Water Reactor may increase the survivability of the cladding material for short transients.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2000

Solid Freeform Fabrication of Continuous Fiber Reinforced Composites for Propulsion Applications

For propulsion related applications, materials must be able to demonstrate excellent ablation and oxidation resistance at temperature approaching 3500'C, adequate load bearing capabilities, non-catastrophic failure modes, and ability to withstand transient thermal shock. A potential list of propulsion-material property requirements includes, low density, high elastic modulus, low thermal-expansion coefficient, high thermal conductivity, excellent erosion and oxidation/corrosion resistance, and flaw-insensitivity. In many cases, they will also need to be able to be joined, survive thermal cycling and multi-axial stress states, and for reusable applications, the materials must maintain the above attributes after prolonged exposure to extremely harsh chemical environments. The final and possibly most important attribute for these materials are the need to be lower cost and readily available in large quantities. Recently, Advanced Ceramics Research, Inc. (ACR) has developed low cost, flexible- manufacturing processes for Zr & Hf-based carbon fiber reinforced composites, materials with good oxidation and ablation resistance up to 3500 C. This process, called Continuous Composite Co-extrusion (C(sup 3)), incorporates carbon fibers to fabricate 'in-situ' carbide and boride-matrix/carbon fiber composites. This is a variation of ACR's manufacturing process for low-cost structural ceramic materials called Fibrous Monoliths With carbon fiber reinforcements. Fibrous Monolithic materials have a distinct fibrous texture, consist of intertwined cells of a primary phase, separated by cell boundaries of a tailored secondary phase and show very high fracture energies, damage tolerance, and graceful failure. Since they are monolithic powder based composites-, they can be manufactured by conventional powder processing techniques using inexpensive raw materials. This combination of high performance and low cost is a breakthrough that could enable wider application of ceramics in high temperature applications. Typical volume fractions of the two phases are 80 to 95% for the cell phase and 5 to 20% for the interpenetrating cell boundary phase. ACR is currently developing an innovative solid freeform form fabrication (SFF) approach to produce Hf and Zr based ceramic composite components reinforced with continuous carbon fiber tows for critical structural components such as tubes and blisks. The process is simple, robust and will be widely applicable to a number of material systems. This technique was originally developed at the University of Delaware Center for Composite Materials (UD-CCM) for rapid fabrication of polymer matrix composites by a technique called automated tow placement or ATP. The current process is being developed in collaboration with UD-CCM. The paper will detail the freeform fabrication process to create low-cost ceramic fiber reinforced composites for high-temperature applications. The results of mechanical properties and microstructural characterization will be presented, together with examples of complex shapes and parts. It is believed that the process will be able to create complex shaped parts for propulsion applications at an order of magnitude lower cost than current CVI and PIP process.

Vaidyanathan, R.↗